iom virgo 3a

8/13/2019 IOM Virgo 3a

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Installation, Operation & Maintenance Manual

CUSTOMER

CONSULTANT

P.P. NO. & DATE

DT. OF DESPATCH

IMPORTANT NOTE:

This manual informs the purchaser of important guidelines ; following these guidelines will be necessary

to ensure proper installation & commissioning of the valve. Guarantee conditions are subject to proper

installation & commissioning of the valve.

GUARANTEE:

The product supplied are covered by guarantee period of calendar months from the date of

dispatch or calendar months from the date of installation whichever is earlier.

VIRGO ENGINEERS LIMITED

Survey No. 277, Raisoni Induatrial Park, Phase-2, Hinjewadi, Pune-57

Phone : (020) 66744000, Fax : (020) 66744021, E-mail:[email protected] Website : www.virgoengineers.com

REV. NO. : 00

PUBLISHED ON :
mailto:[email protected]://www.virgoengineers.com/http://www.virgoengineers.com/mailto:[email protected]


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Installation, Operation & Maintenance ManualVALVE AUTOMATION SYSTEM

1

CONTENTS: PAGES

1. GENERAL INSTRUCTIONS 1 TO 6

2. IOM FOR BALL VALVES. 1 TO 13

3. IOM FOR RACK & PINION ACTUATORS. 1 TO 12

4. IOM FOR HEAVY DUTY ACTUATORS. 1 TO 6

5. IOM FOR MANUAL OVERRIDE 1 TO 3

6. IOM FOR LIMIT SWITCH BOXES. 1 TO 5


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Installation, Operation & Maintenance ManualGENERAL INSTRUCTIONS FOR VALVE AUTOMATION SYSTEM

1

1: INTRODUCTION:-

The purpose of this manual is to ensure that theRemote Operated Valves / Auto. Control Valvessupplied are properly installed and maintained togive trouble-free performance.

To familiarize the end users with the role andfunctioning of various elements like Actuator,Solenoid valves, Limit switches, etc. used to builtup a typical control valve automation system.

To promote better understanding of the productand sort out the minor problems which may ariseon the site.

The scope of these instructions covers three-piece and two piece soft seated floating andtrunnion mounted ball valves, actuators, manualoverride, limit switches.

For better understanding of these instructionsrefer the relevant drawings / views of the aboveelements, where the different parts are identified.

2:RECEPTION AT WORK SITE, STORAGE &

HANDLING PRIOR TO INSTALLATION:-

Previous to shipment all valves will be markedeither directly on the body or on a nameplate orboth, so as to fully identify in accordance withspecifications.

All valves are delivered in the Fail Safe Position &with ends provided with blind covers or plasticcaps, to avoid the entrance of dust, sand othersolid particles during storage/transportation.

Valves will arrive to work site packed & protectedin accordance with packing instructions (pallets,boxes, cartons, etc.). While valves remain packedcare should be taken to store them in a suitableplace considering the packing provided.

Please note that standard external surfaceprotection on valves is only intended fortransportation & storage previous to installation.Once the valve is installed on the line a suitablefinal protection should be applied depending onenvironment conditions, operating temperature,line insulation, etc.

While unpacking, keep the crates upright.Remove top cover, supporting batons carefullyand check the valves for possible damagesduring transportation.

The accessories like handwheel to manualoverride, pressure gauges that are susceptible totansit damages are packed and protectedseparately. Crosscheck the reciept of all theitems & quantity as per packing list.

After unpacking, valves should be stored on a dryplace with good ventilation & dust freeatmosphere. Placing the valve directly on theground or a concrete floor is to be avoided.Valves should never be stored outdoors.

Dont remove the protecting covers untilmounting. If covers are removed for examinationof valve internals, they should be set back inplace immediately.

3:-PRECAUTIONS WHILE MOUNTING, LINE

FLUSHING, TESTING STAGE.

Valves are bi-directional & can be installed ineither position with respect to flow direction. Uni-directional valves will be specifically marked with

the flow direction arrow.

Ensure the pipe ends are concentric and alignedto avoid stresses on the valve body.

Pipe lines must be supported at regular intervalsand preferably near the upstream & downstreamof valve to avoid vibrations.

Make certain that the valves and gaskets are

properly centered to the pipeline. Ensure valve is in desired Fail Safe position.

Refer Tagplate & Data sheet/Spec. sheet tocrosscheck the same. For on-field reversal of FailSafe Position refer, IOM for R & P Actuator.

Avoid mounting with the actuator underneath thevalve.Important!

For installation on vertical pipeline, additional

supports to actuator are recommended to avoid

eccentric forces acting on the stem. This must be

strictly followed for heavy actuators.

Important!

While mounting never separate the valve fromactuator. This will disturb factory set strokes and FailSafe Position of the valves.

Once the valve is installed, do not carry outwelding operations on the upstream side. If this isunavoidable, ensure Ball /Plug valve is retainedin Open Position. Welding burr may deposit on

Caution!

Never lift & shift the valves by the

actuator / tubing or any otheraccessory. Use a sling around the

valve body.

Important!

Normally, it is at the startup of the unit that soft

seated valves can get damaged. Do not install valveson pipelines that have not been flushed & cleaned.


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the seating members and damage the soft partsduring operation.

Open & Close the valve a few times before finaltightening of counter flanges. Apply the torquereferring to the standards for the corresponding

bolt sizes. Ensure pneumatic & electric supplies connected

to actuator, solenoid valves as per the ratedvalues.

Make provisions to ensure that the signal airpressure(3-15 psi) to pneumatic positioner willnever exceed max. allowable pressure 1.5 bar.

Electric cables & air tubing must be routed

properly. Ensure there are no loads, stresses ofcable or pneumatic tube acting on solenoid orpositioner.

Do not overtighten the pneumatic fittings toactuator, air filter regulator, solenoid valve etc..

Always while replacing the lids to limit switchhousings ensure that the indicator dome isengaged properly with the spindle. Indicator

covers to limit switch are of polycarbonate andmay get damaged if subjected to heavy impactsor stresses.

All unused cable entries to limit switch boxesmust be plugged properly to avoid wateringressing.

All cam-switches are factory set to receivefeedback for valve open/close position. Payattention not to disturb the cam setting whileterminating the cable. For re-setting of cams,refer IOM for Limit Switches.

Positioners are factory set & calibrated. Howevera fine tuning while final testing is recommended.Refer IOM for positioner for detailed instructions,which is not included in this book but is suppliedseparately with system.

Read the instruction plate to manual overridecarefully & check the operation.

Check the valve opening/closing through actuator& manual override. Ensure there is no relativemovement between the elements assembled. Re-fasten all the mounting bolts before final testing.

After installation and ensuring correct operation,subject the valve for hydro & pneumatic pressuretests by referring the applicable standards. Iffound necessary, tighten the gland nut at thistime.

To avoid sudden breakdown, malfunctioning,leakage problems, it is recommended to check all

the valves at least once a year for function tests. Replace all soft parts once in two years

irrespective of valve performance. By following all the above instructions, the user is

assured of trouble free & reliable performance ofthe products supplied.

The following sections will further help the user tohave detailed information regarding thefunctioning of individual element, necessaryspares required for maintenance, troubleshootingand the instructions to carry out the same atusers end.

NOTE:-

Refer attached Fig. 1, 2, 3, 4 to get general idea ofautomated systems.

mportant!

pply only clean & dry plant air to ensure trouble

ree services of the actuator over a prolonged period

Important!

lways secure the lids to the solenoid coil, limit

switch housings fully to meet the specified

services(Weatherproof, Flameproof)

Important!

lways ensure the manual override is

declutched prior pneumatic operation.

Important!

Do not apply excessive force through manualoverride for extra closing of valve. Since the

valve strokes are factory adjusted through

actuator, such practice will lead to damages ormalfunctioning of the actuator.


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FIG. 2


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Installation, Operation & Maintenance ManualBALL VALVE

1

1. Introduction

ScopeThe manual is provided to ensure properinstallation, operation & maintenance for the Ball

valves manufactured and supplied by Virgo Groupof Companies. The valves are identified by markingon the body or on a name plate or both.

VIRGOENGINEERS LTD

PUNE,(INDIA)

1.1 Identification of Valve

2. Transportation, Reception and

Storage: While loading & unloading check for any

arrow mark on as indicating upward position.

Always place the valve preferably on rubbersheets layed on ground.

Ensure that all valves ends are covered withprotective end caps.

Always store the valve under roof, in a dry andclean atmosphere, protected from rain & storm.

Before installation of stock valves, it isadvisable to conduct hydrostatic/pneumatictest.

2.1 Storing the Valve

3. Dos and Donts

Dos:

It is recommended always to use the

Installation, Operation & MaintenanceManual before installing, operating orrepairing of any Ball Valve(s).

Use specified/ recommended MOC forspecified application.

Before installation of Virgo Made standardvalve, it is advised for user to ascertain thecompatibility of the material.

Periodically ensure the tightness of Body-Adapter joint bolting, operatability & theelectrical continuity of the valve.

Always use dry, moisture free air while openingthe valve with pneumatic actuator or forcleaning purposes.

Always wear warm clothes while working withcryogenic liquids.

Ensure that thorough ventilation is providedwhile working on the close equipment foroxygen transfer.

Ensure that the end protections are removedbefore installation of valve in line.

Donts:

Do not drag the valve on bare floor.

Do not try to rectify the valve leakage byreworking of seats. Leaking seats have to bereplaced with the new Virgo genuine seats.

Do not allow any such process which maygenerate spark; particularly working in H2or O2service line or any such inflammable fluids.

Do not allow dirt, scales, oil or grease to flowthrough valve & pipeline for oxygen service.

Do not allow to replace (even temporarily) thepressure relieving device which is installed forits intended use by a threaded blind plug.

Do not inhale the cold gases/ fumes for longduration while working with cryogenic liquids.

4. Installation: When taking the valve from the storage a

careful check should be made to be sure thatthe valve has not been damaged duringstorage period. Especially flange faces shouldbe examined in case of flanged end valves.

Valve should be checked for identificationpurpose to make sure that characteristic Matchto those specified for piping specs & for theline where they are to be mounted. Nameplateinstruction and tag nos. (where applicable)should give the necessary information

PUNE,(INDIA)

VIRGO ENGINEERSLTD


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Installation, Operation & Maintenance ManualBALL VALVES

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At this stage valve will have end protector inplace and will be the FAIL SAFE Position.

Before installation, ensure that the valveend protectors are removed & gasket isplaced for Flanged end valves. Clean the

valve ends & bore using methylenechloride or trichloroethylene or as per theCustomers specification.

Clean the pipeline to avoid damage of thesoft seat due to debris, scaling, etc.

Keep the valve in fully open condition.

Never install the Valve with the Actuator onthe underneath side in the pipeline.

4.1 Avoid this mounting position.

4.2 Supporting the valve

While Installing for:

I. Flanged End Valves:

Confirm that mating flanges are parallel &aligned perfectly so that no pipelinemisalignment force are exerted on the valvebody.

Insert valve & locate 3 studs on matching holeon each side. Place the gaskets inside & thenlocate the remaining stud. Finger tighten allnuts into the respective studs.

Now tighten the nut with appropriate size

wrench. Tighten nut in a diagonally oppositesequence & using appropriate torque as perstandards.

Once the installation of the valve in the pipeline isaccomplished, unless the pipeline has beenflushed previously to valve installation, the valveshould not be moved at all from the OPEN position.

II. Weld End Valves:

Pipe ends must be machined to make themsmooth, clean & free from burrs. Keep thevalve in the open position.

Remove the central body assembly consistingof stem assembly, ball, seat and body seals.

Avoid rapid application of excess weldingmaterial.

During welding, weld with a continuous bid.The welding rod should not exceed 3.2mm dia.Size.

After welding, flush the pipe line and valve portto remove impurities formed during welding.Remove any welding spatter also that may

have deposited during welding on the innerpart of the valve.

Welding operations must be done by qualifiedwelder & the welding procedure must beaccording to relevant ASME welding standards.

Dont allow temperature of the valve body seatarea to exceed 200 F (94C). To check thetemperature, use thermal chalks.

a) Butt Weld End Valves:

A proper alignment & a gap g as shown in figure4.7 to get full penetration of weld upto root.

b) Socket-Weld End Valves:

Ensure for proper alignment & a minimum gap of1.6 mm between the pipe end face and the socketweld ends as shown in Figure 4.4.

III. Screwed End Valves:


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Ensure that threads on pipe are of proper size& type.

Clean both male & female thread properly. Useappropriate sealant or Teflon tape while fittinginto the pipe line based on pressure rating to

ensure complete sealing

While installing unidirectional valve in pipeline, check forthe flow direction mark on valve body.

5. Operation of the Valve(s):

Valve should always be rotated through 90 to thefully open or fully closed position. Any intermediateposition will rapidly damage internal and seat of thevalve. Leaving the valve in the nearly close positionshould special be avoided as high fluid velocitythrough the narrow opening will produce erosion ofseat of ball & even the body in some cases.

6. Flushing of Lines and testing of valves:

1. If flushing of pipe line has not been made previous to

valve installation, then it should be done before thevalve are operated for the first time to avoid solidcoming to contact with the seats or depositing in thevalve cavity.

2. Once the flushing is complete the valve should beoperated 3-4 time & then left in the OPEN position.

3. All valves are factory tested & inspected priordispatch. Should it be necessary to test the piping

system with the valve in position, special careshould be taken not to damage them. Body of thevalve should be tested to 1.5 times of the MaximumAllowable Working Pressure (MAWP) of pressureclass.

7. Preventive Maintenance

Periodically check for any damage to valveseats, ball & stem of the valve.

While doing periodical checks, it isrecommended that the seats, gaskets, seals andpacking should be replaced by genuine spares.

A repaired valve is always subjected to set oftests before installation.

Emergency Sealant Injection System in TrunnionMounted Ball Valves:

Sealant injection system is provided on valve

seat or stem packing area to carryout temporaryshut off for maintenance or other purpose.

This secondary sealant injection system is to beused only when damage has been caused to theseats & seals by the hard particles or dirt in theprocess media.

Always flush the sealant port with suitable valvecleaner, before injecting sealant.

Refer sealant injection fitting arrangement asshown in Figure No. 6.1

6.1 Sealant Injection Fitting Arrangement


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10.General Instructions for Disassembly & &

Reassembly of Valves :

.

A) DisassemblyTrunnion Mounted Ball

Valves:

1. Disconnect pneumatic and electric supply toautomation assembly. Remove it(Includingbracket & coupling) from the valve.

2. Valve shall be positioned vertically by restingbody side flanges on clean ground surface

(preferably covered with rubber sheet).3. Open the body adapter joint by loosening theNuts in crisscross pattern

4. Remove the body seal from the body adapterand body gasket from the body.

5. Remove the ball from the body & the seatsfrom body & body adapter.

6. Remove the stem by removing stem holdingdevices as applicable.

7. Push stem into Body cavity & take it out.8. Remove all stem seals.9. All the components should be stored in a clean

place.10. Remove the trunnion by removing the cap

screws.11. Remove the antistatic spring, the thrust washer

(trunnion), the gasket (trunnion) & the O-ring(trunnion).

12. Remove the ball from the body.

Warning!Lifting & shifting of ball must be carried withutmost care, even a minor scratch on the ballsurface may affect performance of the valve.

13. Remove bush bearing from bearing bore in ballon both stem & trunnion side.

14. Remove the O-ring (body adapter) & gaskets(body) from the body adapter.

15. Remove the seat + insert from the body & bodyadapter.

16. Remove the springs, seat O-ring from theseat.

17. Where applicable the sealant injection fittings[(stem) & (seat)] & drain/vent plugs may beremoved for cleaning.

B) ReassemblyTrunnion Mounted Ball

Valves: Before reassembly, inspect the valve for any

damage on Body-Adapter & all internals.

Damaged internals to be replaced by genuine

& with recommended parts only.

1. Follow the same step as mentioned in A) 2).2. Apply suitable coat to bolting to prevent

corrosion.3. Insert body seats in position.4. Insert the stem seal bottom & the stem O

rings on the stem & install the stem from insidethe body.

5. Insert the top stem seal, the spacer, the discsprings or stem bush into the stem asapplicable.

6. Ensure proper locking of stem with lock nut,washer or mounting plate as applicable.

7. Align stem A/F parallel with the body bore.8. Gently slide the ball over the stem A/F.9. Place seal & seat in body adaptor.10. Position the gasket with the body & position

studs.11. Assemble the valve by putting adapter on the

body & tighten the body nuts in a crisscrosspattern.

12. Put the automation in position into body &tighten them.

13. Ensure open and close smooth operation ofvalve.

14. Fit the antistatic spring, the thrust washer(trunnion), the gasket (trunnion) & O-ring

(trunnion).15. Fit the bush bearing into the recess in ball onboth stem & trunnion side.

16. Lift the ball & lower it into the body in theappropriate position.

17. Locate the trunnion in ball recess & tighten thecap screws.

18. Lift the valve & place it so that the direction ofthe flow axis is horizontal.

19. Locate the dowel pins & place the stemhousing on the body, so that the stem housingfits into the bush bearing & stem flats locates inthe ball slot.

20. Place & tighten the cap screws for stemhousing.

21. Fit the body adapter gently upto with seat tothe body & tighten the nuts. Put the studs inposition into body & tighten them.

22. Fit the gasket (stem) in the stem housingrecess.

23. Place the gland on the stem housing & tightenthe cap screws.

24. Fit the stem key in stem key way.25. Place the coupling on the stem, place the

bracket on the stem housing, fit the studs &

CAUTION !

Pipeline and valve must be depressurized byshutting off the valves & the bleed line, thencycling the valve once & leaving it half opento relieve the pressure from the body cavity


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tighten the nuts. Place the actuator on the coupling &the bracket, fit the studs & tighten the nuts.

26. Where applicable, fit sealant injection fittings [(stem) &(seat)] & the drain/vent plugs.

27. Rotate the ball slowly back & forth to a full quarter turn.This will allow the seat to assume its permanent

position & shape against ball & body. A fast turningmotion may damage the seat before it has a chance toform a proper seal.

C) DisassemblyFloating Ball Valve(two

piece construction):

1) Disconnect pneumatic and electric supply toautomation assembly. Remove it (Including bracket &coupling) from the valve.

2) Valve shall be positioned vertically by resting body sideflanges on clean ground surface (preferably coveredwith rubber sheet).

3) Open the body adapter joint by loosening the Nuts incrisscross pattern.

4) Remove the body seal from the body adapter and bodygasket from the body.

5) Remove the ball from the body & the seats from body &body adapter.

Warning!Lifting & shifting of ball must be carried with utmostcare, even a minor scratch on the ball surface mayaffect performance of the valve.

6) Remove the stem by removing stem-holding devicesas applicable.

7) Push stem into Body cavity & take it out.8) Remove all stem seals.9) All the components should be stored in a clean place.

D) ReassemblyFloatingBall Valves(two

piece construction):

Before reassembly, inspect the valve for any damageon Body-Adaptor & all internals.

Damaged internals to be replaced by genuine & withrecommended parts only.

1. Follow the same step as mentioned in A) 2).2. Apply suitable coat to bolting to prevent from

corrosion.3. Insert body seats in position. Insert the stem seal

bottom & the stem O rings on the stem & install thestem from inside the body.

4. Insert the top stem seal, the spacer, the disc springs orstem bush into the stem as applicable.

5. Ensure proper locking of stem with lock nut,

6.washer or mounting plate as applicable.

7. Align stem A/F parallel with the body bore.8. Gently slide the ball over the stem A/F.9. Place seal & seat in body adaptor.10. Position the gasket with the body &

position studs.

11. Assemble the valve by putting adapter on thebody & tighten the body nuts in a crisscross

pattern.12. Put the automation assembly in position into

body & tighten them.13. Ensure smooth operation of valve during

opening and closing.

E) DisassemblyFloating Ball Valve

(Three piece construction):1. The swing-through design of three piece ball

valve facilitates on-line repair And replacement ofsoft parts.

2. Disconnectpneumatic & electric supply toautomation assembly. Remove it (includingbracket & coupling) from the valve.

3. Remove the valve body Nut Bolt (3 no .s) andonly loosen but do not remove remaining nut-bolt.

4. Keep the valve in the full OPEN position.5. The Body can now be sung out of the pipeline.6. Remove the Body Gasket & Seat on both side7. Rotate the stem to turn Ball to full CLOSE

position. Push out the ball from the body.8. Remove the Stem Nut , Disc Springs , Spacer ,

over the stem.9. Push the stem to remove it from inside the body.

Remove the Bottom & Top Stem Seal from the

body.10. Clean the ball, valve body & end pieces internalwith suitable & permissible liquid like petrol,kerosene etc and cloth. Clean the seat and sealswith cloth only. Place all the above part on theclean & dust free platform

11. Examine metallic part to ensure that there are noscoring on the sealing surfaces. Check the sealsfor scratches/wear.

12. All part that are recommended as seal kit to bereplaced with new one whenever the valve is dis-assembled.

F) Reassembly Floating Ball Valve

(Three piece construction):

1. Place the Bottom Stem Seal , Stem , TopStem Seal ,Disc Spring , Spacer & Stem Nutby following step # 7 & 8 at E) in exactlyreverse order.

2. Tighten stem nut so as to pressurize /compress the disc springs. Over tighteningmay result in stem locking.

3. Slide the ball in the body in such a way that


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the stem location slot on the ball locates inthe flat of the stem.

4. Rotate the stem to keep ball in the full OPENposition. Fit the seats & Body Gaskets on eitherside of the ball.

5. Ensure the seats & seals are located properly

and will not foul with the end piece and thenswing the body to its original position.

6. Pass the Body Bolts & finger tighten the NutTighten all the nuts equally and diagonallyusing appropriate wrenches & torques.

7. Subject the valve for pressure testing, if anyleakage observe through body joints or gland,further tighten the body nut and stem nut.

8. Re-install the automation assembly and checkthe operation.


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10. Exploded view:Two Piece Design Floating Ball Valves ( With Double D Stem)

Parts List

ITEM PART NAME01 Body RECOMMENDED TIGHTENING TORQUES, Kg.m (Nm)

02 Body Adapter03 Ball

ThreadSize

PropertyClass 8.8

PropertyClass 10.9

B7/B7M

04 Stem M8 2(20) 2.9(28) 2(18)* 05 Seat M10 4(40) 5.7(56) 3(30)* 06 Body Seal M12 7(69) 10(98) 5(51)* 07 Body Gasket M14 11.3(111) 15.9(156) 11(103)* 08 Stem Seal Bottom M16 17.2(168) 24.2(237) 12(121)* 09 Stem O Ring M18 24.4(239) 34.3(336) 20(194)* 10 Stem Seal Top M20 33.5(329) 47.2(463) 24(236)11 Spacer Ring M24 57.9(568) 81.5(799) 42(408)12 Disc Spring M27 87.5(858) 123(1207) 61(597)13 Stem Nut M30 115.9(1137) 163(1599) 83(814)

14 Stud

15 Nut

Note: Ensure that all the nuts/bolts are tightened to the TorqueValues as specified in this Table.For B8/B8M consider Tightening Torque 20% less thanabove values

* Recommended spare parts.

Note:Always use the genuine spare parts to make sure that the valve functions as intended.


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11. Exploded view:Three Piece Design Floating Ball Valves

Parts & Fastener TorquesITEM PART NAME

01 BodyRECOMMENDED TIGHTENING TORQUES, Kg.m (N.m)

02 Pipe End03 Ball

ThreadSize

PropertyClass 8.8

PropertyClass 10.9

B7/B7M

04 Stem M8 2 (20) 2.9 (28) 2 (18)* 05 Seat M10 4 (40) 5.7 (56) 3 (30)

06 Seat Ring M12 7 (69) 10 (98) 5 (51)* 07 Body Gasket M14 11.3 (111) 15.9 (156) 11 (103)* 08 Stem Seal Bottom M16 17.2 (168) 24.2 (237) 12 (121)* 09 Stem Seal Top M18 24.4 (239) 34.3 (336) 20 (194)

10 Spacer Ring M20 33.5 (329) 47.2 (463) 24 (236)

11 Disc Spring M24 57.9 (568) 81.5 (799) 42 (408)12 Stem Nut M27 87.5 (858) 123 (1207) 61 (597)13 Studs M30 115.9 (1137) 163 (1599) 83 (814)14 Nuts

Note: Ensure that all the nuts/bolts are tightened tothe torque values as specified in this Table.

For B8/B8M consider Tightening Torque 20% less thanabove values

* Recommended spare parts.



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12. Exploded view:Two Piece Design Floating Ball Valves

Parts ListITEM PART NAME

01 Body RECOMMENDED TIGHTENING TORQUES, Kg.m (Nm)

02 Body Adapter

03 Ball

ThreadSize

PropertyClass 8.8

PropertyClass 10.9

B7/B7M

04 Stem M8 2(20) 2.9(28) 2(18)

* 05 Seat M10 4(40) 5.7(56) 3(30)

* 06 Body Gasket M12 7(69) 10(98) 5(51)

* 07 Body Gasket M14 11.3(111) 15.9(156) 11(103)

* 08 Stem Seal Bottom M16 17.2(168) 24.2(237) 12(121)

* 09 Stem O Ring M18 24.4(239) 34.3(336) 20(194)

10 Stem Bush M20 33.5(329) 47.2(463) 24(236)

11 Body Stud M24 57.9(568) 81.5(799) 42(408)

12 Body Nut M27 87.5(858) 123(1207) 61(597)

13 Stem Key M30 115.9(1137) 163(1599) 83(814)

Note: Ensure that all the nuts/bolts are tightened to the TorqueValues as specified in this Table.

For B8/B8M consider Tightening Torque 20% lessthan above values.* Recommended spare parts.



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13. Exploded view:Two Piece Design - Trunnion Mounted Ball Valves



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14. Exploded view:Three Piece Design - Trunnion Mounted Ball Valves



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Ordering the sparesWhen ordering for spare parts, always convey the following information.

Size of the valveValve rating

Sr. No. / Batch No.Mfg. Date

Available on name plate or body of the valve

Part No.Name of the partNumber of pieces required.

P. O. Number

Available on general arrangement drawing

Trouble ShootingThe following table lists the possible malfunctions that might occur after prolonged use.

Possible fault Actions

Damaged ball surface Replace the ball.

Damaged seats Replace seats.

Leakage through a closed

ValveBall might not be closedfully

Check ball Open/Closesettings.

Flush the ball from inside.Irregular ball movement Impurities between the balland seats or ball bodycavity and ball Seats.

Clean the sealing surfacesand seats.

Damaged seats Replace the seats.

High application pressure /temperature

Confirm the applicationpressure /temperaturerating.

Valve too hard to operate/ valve torque too high

Foreign particles in Valve Clean the internals.

Water hammer or noisyoperation

Error in valve sizing or flowof fluid with high velocity.

Confirm valve sizing withrespect to flow.

Gland nut loose Tighten gland nut.

Damaged stem, stemsealing surface

Replace the stem.

Leakage through stem

Damaged stem seal Replace the stem seal.

Damaged O ring orbreakage of gasket

Replace O ring/ gasket.Leakage through body-adaptor joint

Relaxation of studs due togasket creep

Retighten the studs evenly incriss-cross manner


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Note: Selection and use of the valve for a specific application requires close consideration of detailedaspects. Due to the nature of the product, this manual cannot cover all the individual situations that mayoccur when installing, using or servicing the valve.

Warranty:

Our liability in respect of any defect in or failure of the goods supplied or for any loss, injury or damage attributablethereto is limited to making goods by replacement or repair defects which under proper use appear therein andarise solely from faulty materials and workmanship within a period of 18 calendar months after the original goodsshall have been first dispatched or 12 calendar months from the date of commissioning, whichever is earlierprovided that such defective parts are returned free to our works for examination. The undertaking shall excludeany and every other obligation.

Caution!

Virgo does not assume responsibilities for any liabilities/damages arriving out of wrong application of its valves, orimprudent operations carried out by inexperienced operators, or which does not comply with this manual ,orinstructions provided by Virgo.

The valves shall be appropriately used for the purpose they are built, or applications they are supplied. Use ofstandard valves for special applications is not recommended unless it has been communicated and agreed to byVirgo.

Valves shall be operated and maintained strictly in accordance with the procedures. Operation or maintenanceoutside these procedures constitutes abuse of the product and voids all warranty and claims.


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Installation, Operation & Maintenance Manual2V SERIES RACK & PINION ACTUATORS

1

1. General:

This manual contains the important information regarding

the installation, operation and troubleshooting of theVirgo 2V pneumatic actuators. Please read these

instructions carefully before operating the actuator.

Warnings!

It is important that the actuator should only beused within the pressure limits indicated in ourtechnical specifications.

Operating the actuator over pressure limits willdamage internal parts as well as cause damageto the housing.

Operating the actuator over temperature limitswill damage internal and external components(disassembly of spring return actuator may

become dangerous). Operating the actuator in corrosive environments

with incorrect protection may damage the internaland external parts.

Do not disassemble the individual springcartridges. Disassembly may result in personalinjury.

Isolate all airlines and make sure that actuator airconnection is vented before installation orservicing of the actuator

Do not remove end caps or disassemble theactuator while the actuator is pressurized.

Before installing onto a valve, make sure that the

rotation of the valve and the actuator are thesame and that the position indicator orientation isalso correct.

If the actuator is in a system or used within safetydevices or circuits, the customer shall ensurethat the national and local safety laws andregulations are observed.

2. Technical Data:

Operating Media: Dry or lubricated air, non-corrosive and inert gas, or light hydraulic oil.Air Supply: 8 bar (116 PSI) Maximum.Temperature:

Standard: -4 F to 175F (-20C to 80C)

Viton O Rings : -4 F to 300F (-20C to 150C)

Siilicon O Rings : -40 F to 175F (-40C to 80C)Lubrication: Factory lubricated for the life of theactuator under normal conditions.Construction: Suitable for indoor and outdoor use.

External Travel Stops: 5adjustment on 90stroke.

3. Installation:

1. Actuator should be stored indoor until ready for

use. Check that the non-connected ports ofactuator are plugged properly with plasticcap/silencer to avoid ingress of dust, dirt,moisture into actuator.

2. Prior to assembly, check the mounting surfaces,coupling, bracket to ensure proper fit. Apply littlegrease to coupling surface.

3. Ensure that the desired failure mode is correct(Refer to figure no. 1,2 & 3). The Virgo 2Vactuator typically operates counter clockwise toopen and clockwise to close, it is possible tochange this style of operation. If the spring returnactuator is not set up in the configuration desired,

follow the disassembly procedure section 5.2.Reverse the orientation of the pistons, thenreassemble following the assembly procedure,section 5.3.

4. Ensure that the valve is in the fail safe position.5. Secure the valve with stem vertical. Bolt the

bracket to valve and place the coupling on valvestem. Use key/dowell pin (according to valvestem design) to engage coupling with the valvestem. Be sure that there is no play between valvestem & coupling.

6. Continue to lower the actuator until it rests on thebracket mounting surface.

7. To align the bolt holes, it may be necessary toturn or to stroke the actuator a few degrees. Boltthe actuator to the bracket by evenly tighteningall four bolts in diagonal pattern.

8. Stroke the actuator to check proper open andclose valve position. If required, further adjust thestroke adjustment bolts following assemblysection 5.3.5. Stroke adjustment bolts can be

adjusted by up to 5.9. Also assure proper operation of actuator with no

binding of coupling. Check for proper alignmentof actuator, coupling and valve stem along theaxis to ensure that pinion is rotating in exactly

circular profile(90.sector). If not so realign theassembly and fix it properly.

10. Ensure that there is no relative movementbetween valve to bracket and bracket to actuator.

Important!Never hammer actuator/pinion for complete engagement of

pinion and coupling. Hammering damages / deforms pinion

permanently. If actuator cannot be lowered easily, file / grind

coupling square faces lightly to ease the engagement


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11. Recommendation: When the valve automationassembly is mounted with valve stem axishorizontal, additional adequate supports must be

provided to the actuator. Failure to do the samecould lead eccentric loads on the valve stem.This must be strictly followed particularly with

heavy actuators.12. If the actuator is equipped with some accessories

like limit switches, speed control valve, adjustthem at this time.

13. Mount the actuator to the valve as per thedesired orientation (parallel or perpendicular tothe pipeline).

14. Connect a regulated air supply to the NPT fittingin the actuator housing.

3.1 Changing Actuator Orientation:

Actuator can be mounted parallel or perpendicular tothe pipeline axis. The standard practice is to mountactuator parallel to pipeline. However factoryassembly is carried out based on customersdata/spec. sheet.

By reffering the following instructions, actuator bodyorientation can be changed on field:

1) Disconnect pneumatic and electric supply toactuator, solenoid valve to release the air fromactuator completely. Ensure the valve is in thedesired fail safe position.

2) Remove mounting bolts at the bottom ofactuator.

3) Lift actuator till it gets free from the coupling.

4) Rotate actuator by 90 and lower it overcoupling.

5) Rest the actuator fully on bracket surface andsecure it with mounting bolts Fasten the bolts.

6) Stroke the actuator 2-3 times pneumatically toensure proper functioning.

4. Operation:

The Virgo 2V actuators have simple operationalcharacteristics. Port A (facing the ports and readingright to left) is connected to the interior cavitybetween the pistons directing the airflow into/out ofthe interior cavity. Port B is connected to the end

cap cavities directing airflow into/out of the end caparea.

4.1 Double Acting (Figure 1): (Double airconnection required to achieve both actions- opening& closing). Air supplied through port A forces the

piston away from each other causing the pinion torotate counter clockwise (with exhaust air exitingthrough port B). Air introduced through port Bforces the piston towards each other causing thepinion to rotate clockwise (with exhaust air exitingthrough port A).

4.2 Spring Return: Singleair connection required forone action, the reverse is achieved with springs

4.2.1 Fail Clockwise (FCW) (Standard Scope ofSupply) (Figure 2): Air introduced through port Aforces the piston away from each other, compressingsprings and causing the pinion to rotate counterclockwise (with exhaust air exiting through port B).

Upon loss /release of air pressure, springs forces thepiston towards center position causing pinion torotate clockwise (FCW) (with exhaust air exitingthrough port A).

4.2.2 Fail Counter Clockwise (FCCW) (Figure 3) :Air introduced through port A forces the piston away

Caution!The maximum operating pressureis116 psi (8 bar)


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3

from each other, compressing springs and causingthe pinion to rotate clockwise (with exhaust air exitingthrough port B). Upon loss /release of air pressure,springs forces the piston towards center positioncausing pinion to rotate counter clockwise (FCCW)(with exhaust air exiting through port A).

4.3) Changing fail safe position:Valve automation system is always assembled tomeet desired fail safe position (fail to open/close) asper customer spec. sheet. However the specialdesign feature of actuator offers on-line conversion offail safe position. Refer the following instructions:

4.3.1) Assembly with valve + Actuator:1) Disconnect pneumatic & electric supply to

actuator and ensure air is not blocked / trappedinside actuator.

2) Remove mounting bolts from actuator bottom

and lift the actuator till it is disengaged fully fromthe coupling.

3) Rotate the valve stem through 90to change itsposition(close to open or vice versa).

4) Re-install actuator. Secure it properly bytightening the mounting bolts.

5) Stroke actuator pneumatically 2-3 times toensure the desired fail safe condition is achieved.

6) If limit switches, positioners are provided,readjust the same.

4.3.2)Assembly with Valve + Manual Override (GearBox) + Actuator:

1) Follow steps #1 through 6 referred in 4.3.12) Refer IOM for Manual Override to follow the

further instructions to re-align gear box afterchanging fail safe condition of valve.

5 Maintenance:

5.1 General :Virgo 2V actuator can be supplied with Metric / UNCfasteners. Under normal operating conditions, theactuator requires only periodic observation to ensure

proper adjustment. Parts included in seal kit & repairkit are indicated on table 3.

5.2 Disassembly:

When disassembly of the actuator is required formaintenance, remove the actuator from the valve.Ensure proper lifting procedures are followed whenmoving or carrying actuators.

.

When disassembling the Virgo 2V actuators, usecaution and be certain that the actuator is free fromaccessories and the air supply is disconnected.When the actuator is a spring-return unit, makesure that the actuator is in the failed position beforedisassembling.

5.2.1) Removal of Local Position indicator (28)(Figure 4) :

a) Remove the counter sunk screw (29), if fitted.b) Remove the Local position indicator (28) from the

pinion (05). It may be necessary to pry gentlywith a screwdriver.

Important!

The above method holds good only for quarter turn,

bi-directional valves like Ball valve, Butterfly valve

with centric disc design, plug valve. By changing

fail safe condition, the 90sector of valve operation

gets shifted. The same is not recommended for the

valves with special design like Butterfly valve with

eccentric disc, Segment Ball valve, Unidirectionalvalves. Adopting above method for such valves

may damage the valve permanently. For changing

fail safe condition of such valves , change the

piston orientation on both sides by 180.

Caution!Do not use M5 VDE/VDI mountingholes for lifting the actuator


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5.2.2) Removal of Top Cover Plate (19) Assembly(Figure 5) :

a) Remove the counter screws (17).b) Remove the top cover plate (19) from the pinion

with the help of knurling provided on Top CoverPlate. It may be necessary to pry gently with ascrewdriver.

c) Remove the top cover plate O ring (20) anddiscard, if replacing soft parts.

5.2.3) Removal of Stroke Adjustment Bolts (12)( Figure 6):

a) Remove both the Stroke Adjustment Bolts (12)together with nut (13) and washer (14). Replacethe Stroke Adjustment Bolts (12) in case ofexcessive wear observed on the bolt surface.

5.2.4) End Cap (02,03) Disassembly (Figure 7):

a) Remove the end cap bolts (15) in the sequenceshown in the figure 7.

b) For spring return actuators, remove springcartridges (26).

c) Remove end cap O rings (24) and discard ifreplacing all soft parts.

5.2.5) Piston (04) Disassembly (Figure 8):

Caution!:When disassembling a spring returnactuator, the end cap (02,03) should be looseafter unscrewing end cap bolts (15) 4-5 turns.If there is still force on the end cap bolt (15),this may indicatea damaged spring cartridgeand any further disassembly should bediscontinued. Further disassemblyof the endcaps may result in serious personal injury.Return the actuator to Virgo for further


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a) Hold the body (01) in a vice or similar device.Rotate the pinion (05) until the pistons (04) reachthe end positions (i.e. the piston rack teethdisengages with pinion teeth).

Caution!:Air pressure should not be used to remove

the pistons from the body.

Clean and inspect the piston teeth for signs ofwear. Replace pistons, if wear seems excessive.

b) Remove piston O rings (23), piston guide band(07). Discard the O rings and guide band, ifreplacing the soft parts.

5.2.6) Removal of Pinion (05), Cam (11) andbearings (08,09) (Figure 9) :

a) Remove the circlip (25) using a circlip plier.b) Remove the cam rotating washer(31), cam (11),

cam bearing (10). It may be necessary to prygently to cam with a screwdriver. Observe thecam surfaces for excessive wear, where the

Stroke adjustment bolts are resting and the camID (Square c/s). Replace the cam, if excessivewear is observed.

c) Apply a downward force to top of the pinion (05)so that the pinion will move completely out of thebottom of the body (01). If the Pinion (05) doesnot move freely, gently tap with a plastic mallet.

d) Remove the top and bottom bearings (08,09) andtop and bottom O rings (21,22). Discard ifreplacing all soft parts.

5.2.7) Cleaning and inspection:

When all components are disassembled, those notbeing replaced should be properly cleaned andinspected for wear prior to re-assembly.

5.3 Assembly:Prior to assembly, ensure that all components areclean and undamaged.It is recommended to use the lubricants asmentioned in Table 2.

Table 2: Recommended Lubricants

General Use CASTROL GREASE - AP3

5.3.1) Pinion (05) Assembly (Figure 10) :

a) Install the top and bottom bearings (08,09) andO rings (21,22) onto the pinion (05).

b) Apply grease to the pinion bearings (08,09), shaftO rings (21,22) using general-purpose greaselisted in table 2.


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c) Insert the pinion (05) into the body (01) from thebottom side. Ensure that bottom surface of thepinion should be around 0.5mm inside the bodybottom face and the pinion top slot orientation isas shown in figure 11.

5.3.2) Piston (04) Assembly (Figure 12 & 13):

a) Fit piston pad (06), piston guide band (07), pistono-rings (23) on the pistons (04).

b) Apply grease to the internal bore of the body (01)& to the piston rack teeth using recommendedgeneral - purpose grease listed in table 2.

c) Press the two pistons simultaneously in the bodybore until the pinion racks are engaged androtate the pinion until the stroke is completed.Take care that the pistons are oriented correctlyas per the fail position of the actuator (Thestandard fail action of actuator is fail clockwise).Refer Fig 12 & Fig 13.

d) To ensure that the piston (04) teeth are evenlyengaged, fully compress both the pistons inwardand measure the distance from the edge of thebody to the piston (04) face on each side, shownas dimension A in figure 13. If a different value

is obtained on each side, remove the pistons andrepeat from step 2c.

e) Temporarily install the local position indicator(28) onto the pinion (05) to determine whetherthe correct stroke is obtained. Ensure that thearrow in the local position indicator (28) will

rotate a minimum of 5 beyond the 90 verticalcenterline of the actuator body (01) and a

minimum of 5 beyond the 0 horizontalcenterline of the actuator body as shown in figure

14. If the proper stroke is not obtained, removethe pistons and repeat from step 2c. Once properstroke is obtained, remove the local positionindicator (28).


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5.3.3) Cam (11) Assembly (Figure 15):

a) Insert the cam bearing (10) and cam (11).Ensure that the cam orientation is as shown inthe figure 15.

b) Insert the circlip (25) using the circlip plier.

SPRING RETURN ACTUATORS.

For spring return actuator, insert the properquantity of the spring cartridges (26) according tothe pattern shown in Fig 16 (referring to thetotal number of springs). Insert the springcartridges (26) as shown in Fig 17.

Apply grease to the end cap O rings (24). Fit the

O rings (24) into the groove in each end cap(02,03). Fit the Plug Transfer port (30) inside thebody (01) on each side. Fit the end caps. Insertall the end cap bolts (15) and hand tighten.Complete tightening by following the sequenceindicated in Fig 18.

DOUBLE ACTING ACTUATORS.

Apply grease to the end cap O rings (24). Fit theO rings (24) into the groove in each end cap(02,03). Fit the Plug Transfer port (30) inside thebody (01) on each side.

Fit the end caps (02,03) onto the body (01),verifying that the O rings (24) remain in thegroove. Insert all the end cap bolts (15) and handtighten. Complete tightening by following thesequence indicated in Fig 18.


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5.3.4) Assembly of Stroke Adjustment Bolts (12)

a) Insert the nut (13), washer (14) onto the strokeadjustment bolt.

b) Screw in the bolts (12) into the body (01).

5.3.5) External Travel Stop Adjustment (Figure19) :

The stroke adjustment bolt to the right controls theclockwise end of travel, while to the left controlsthe counter-clockwise end of travel.

a) Cycle the actuator to the clockwise end of traveland determine if the pinion top slot is in theproper position (In most of the applications thiswill be perpendicular to the actuator body i.e. at90

0)

b) If the pinion top slot is not in the correct position,turn the right stop adjustment bolt (12) IN to

reduce actuator travel, or OUT to increaseactuator travel.c) When the correct clockwise position is obtained,

hold the adjusting bolt (12) stationary whiletightening the nut (13).

d) Cycle the actuator to the counter-clockwise endof travel and measure to determine if the piniontop slot is in the proper position. (In most of theapplications, this will be parallel to the actuatorbody i.e. at 0

0).

e) If the pinion top slot is not in the correct counter-clockwise position, turn the left stop adjustmentbolt (12) IN to reduce actuator travel, or OUT toincrease actuator travel.

f) When the correct counter-clockwise position isobtained, hold the adjusting bolt (12) stationarywhile tightening the nut (13).

5.3.6) Top Cover Plate Assembly (Figure no 20):

Paste the top cover plate gasket (18) to the topcover plate (19) by using suitable paste/solution.

Fit the O ring (20) using grease inside the topcover plate.

Insert the top cover plate (19) onto the pinion(05).

Fit the three counter sunk screws (17) on thecover plate.

5.3.7) Local Position indicator Assembly (Figureno 21):

Fit local position indicator (28) assembly onto thepinion (05). Ensure that it indicates the correct

Actuator position.

Tighten the counter sunk screw (29) to securethe local position indicator.

5.3.8) Actuator Lock Out Arrangement :

For 052-100 Models (Refer to fig no-23 & 24):

To lock the actuator at fully closed condition,cycle the actuator to clockwise end of travel, tillthe counter on the cam is inline with backsidetapping. Rotate the right stroke adjustment boltOUT & left stroke adjustment bolt completely IN.(Refer to fig No-23)

To lock the actuator at fully opened condition,cycle the actuator to counter clockwise end oftravel. Rotate the left stroke adjustment bolt OUT

& right stroke adjustment bolt completely IN.(Refer to fig No-24)

For 115-270 Models (Refer to fig no-25 & 26):

To lock the actuator at fully closed condition,cycle the actuator to clockwise end of travel, tillthe counter on the cam is inline with backsidetapping. Rotate the right stroke adjustment boltOUT. Insert the locking bolt from backside asshown in fig no 25.

To lock the actuator at fully open condition, cyclethe actuator to counter clockwise end of travel, tillthe counter on the cam is inline with backside

tapping. Rotate the left stroke adjustment boltOUT. Insert the locking bolt from backside asshown in fig no 26.


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5.4 Mounting of Insert : Following procedure givesguidelines for assembly / disassembly of serratedpinion and serrated inserts.a) Drive By Square Head : refer fig. 27 (a) & (b).b) Drive By Double D / Flat Head: Refer Fig. 28 (a)

& (b). (Reference Standard: DIN EN ISO 5211).

Please follow above orientation for serrated insertand local position indicator as per yourrequirements.

5.4.1. Disassembly of Inserts:1) Mount appropriate insert removing tool (33) on rod(35) as shown in figure. (e.g. For Insert 30x22

Double D, select insert removing tool of marking30x22 ).2) Guide insert removing tool (33) in cavity of insert(32) (e.g. double D ) as shown in figure 29.3) Turn insert removing tool by 90

othrough rod (35)

and blow hammer (34) upward / direction shown infigure (29).4) Insert (32) will come out from pinion serrationafter hammer blow.5.4.2. Assembly of Insert on Pinion:1) As per finaloutput drive requirement, match the insert (32) onpinion serration (05). Two dots are provided oninsert(32) & one on pinion (05) so that one can

perfectly match Double D, Square drive properly.See fig. 27 (a), (b) & fig. 28 (a), (b).2) For diagonal square drive, make inserts (32)square diagonal i.e. diagonal of square & actuatoraxis should be inline. See fig. 27 (b).3) After matching required output drive, hammerinsert by rubber mallet (not shown in figure).


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6. Storage :

All the Virgo 2V actuators are factory lubricated for one million cycles under normal operating conditions. Theports are plugged to prevent material from entering the actuator during the shipment. If the actuators are not for

immediate use, the following precautions must be taken during storage.a) Store in a dry environment.b) It is recommended that the actuator be stored in its original box.c) Do not remove the plastic plugs on the air supply ports.

6. Trouble shooting:

A) Valve not operating:1 Confirm specified air pressure is supplied to actuator for which actuator is sized/selected. Refer tag plate.

2 Increase air pressure by 1-1.5 KG/cm2than specified . Observe the performance. If valve operates at thisincreased pressure, valve servicing is required.

3 If still valve does not operate, isolate actuator from valve. Connect air & observe performance of actuatorindependantly. If actuator strokes, valve servicing is required.4 If isolated actuator does not operate, call / report to M/S VELs service cell for actuator rectification.

B) Valve got struck:1) Bypass all accessories like solenoid, positioner quick exhaust valve, speed control valve & apply air direct to

actuator ports. If valve/actuator operates, re-assemble accessories one by one & go on testing. Try to locatedefective accessory & replace it.

2) If actuator does not stroke even after applying air directly, isolate it from valve. Try to operate valve 2-3 timesmanually. Re-install actuator. Apply air pressure (higher than specified). Now if actuator strokes, valveservicing is required & if not report to M/S VEL.

C) Actuator does not stroke fully/Actuator operation found sluggish:1) Even after isolating actuator from valve & applying excess pressure, if this observation persists, check for air

bleeding from the port B, between body-End cap joint, between stroke bolt-end cap.

2) Ensure grease inside actuator is not contaminated with moisture or water. Clean actuator inside & re-grease it.3) If still actuator performance is not improved, report to VEL.

WARNING!M/S VEL does not take any responsibility, if in case it is found that the actuator is damaged inattempting to dis-assemble it at Customers end.

Important!If such leakages are observed, actuator torque output will be reduced and valve will not operate. Replace all seals with new one


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D:\1483\My Documents\My Documents\IOM FOR Printing Revised\2V SERIES.doc 12

Seal Kit consist of:- Item No. 20, 21, 22, 23, 24. Repair Kit consist of:- Item No. 06, 07, 08, 09, 10, 18, 20, 21, 22, 23, 24, 25, 30.


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Installation, Operation & Maintenance ManualHEAVY DUTY ACTUATORS

1

1. General:

This manual contains the important informationregarding the installation, operation andtroubleshooting of the Heavy Duty Actuatorspneumatic actuators. Please read these instructionscarefully before operating the actuator.

Warnings! :

It is important that the actuator should only beused within the pressure limits indicated in ourtechnical specifications.

Operating the actuator over pressure limits willdamage internal parts as well as cause damageto the the housing.

Operating the actuator over temperature limitswill damage internal and external components(disassembly of spring return actuator maybecome dangerous).

Operating the actuator in corrosive environmentswith incorrect protection may damage the

internal and external parts. Do not disassemble the spring cartridges.

Disassembly may result in personal injury.

Isolate all airlines and make sure that actuator airconnection is vented before installation orservicing of actuator.

Do not remove end caps or disassemble theactuator while the actuator is pressurized.

Before installing onto a valve, make sure that therotation of the valve and the actuator are thesame and that the position indicator orientation isalso correct.

If the actuator is in a system or used withinsafety devices or circuits, the customer shallensure that the national and local safety lawsand regulations are observed.

2. Technical Data:

Operating Media: Dry or lubricated air, non-corrosive and inert gas or light hydraulic oil.Air Supply: 7 bar (100 Psi) Maximum.Temperature:

Standard: -4 F to 175F (-20C to 80C)

Viton O Rings: -4 F to 300F (-20C to 150C)

Silicon O Rings: -40 F to 175F (-40C to 80C)Lubrication: Factory lubricated for the life of the

actuator under normal conditions.Construction: Suitable for indoor and outdoor use.

External Travel Stops: +5(On Both Directions)

adjustment on 90stroke.

3. Installation:

1. Ensure that the desired failure mode is correct(Refer to figure no. 1,2 & 3). The Heavy DutyActuator actuator typically operates counterclockwise to open and clockwise to close, it is

possible to change this style of operation. If thespring return actuator is not set up in theconfiguration desired, follow the disassemblyprocedure section 6.1. Reverse the orientation ofthe yoke, then reassemble following theassembly procedure, section 6.2.

2. Mount the actuator to the valve as per the

desired orientation (parallel or perpendicular tothe pipeline).

3. Connect a regulated air supply to the NPT fittingin the actuator housing.

Caution! :The maximum operating pressure is 100 Psi (7 bar).

4. Adjust the stroke adjustment bolts followingsection 15. Stroke adjustment bolts can be

adjusted by up to +5on both directions.

4. Operation:The Heavy Duty Actuator actuators have simpleoperational characteristics. Operation is done bysupplying air through two ports. Port B (facing theports and reading right to left) is connected to theinterior cavity between the pistons directing theairflow into/out of the interior cavity. Port A isconnected to the end cap cavities directing airflowinto/out of the end cap area.

4.1 Double Acting (Figure 1):Air supplied throughport A forces the piston, causing the yoke to rotatecounter clockwise (with exhaust air exiting throughport B). Air introduced through port B forces the

piston, causing the yoke to rotate clockwise (withexhaust air exiting through port A).

4.2 Spring Return:

Fail Clockwise (FCW) (Standard Scope of Supply)

(Figure 2):Air introduced through port A forces thepiston away, compressing springs and causing theyoke to rotate counter clockwise (with exhaust airexiting through port B). Upon loss /release of airpressure, springs forces the piston towards originalposition causing yoke to rotate clockwise (FCW)(with exhaust air exiting through port A).


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4.2.2 Fail Counter Clockwise (FCCW) (Figure 3):Air introduced through port A forces the pistonaway, compressing springs and causing the Yoke torotate clockwise (with exhaust air exiting through portB). Upon loss /release of air pressure, springsforces the piston towards original position causingyoke to rotate counter clockwise (FCCW) (withexhaust air exiting through port A).

5 Maintenance:

5.1 General:Heavy Duty Actuator actuator is supplied with Metricfasteners. Under normal operating conditions, theactuator requires only periodic observation to ensureproper adjustment. Service kits are available toreplace seals and bearings (soft parts). These partsare identified in Figure 10 and listed in Table9.Consult factory for repair Kits.

6 Disassembly and Assembly

Instructions :

6.1 Disassembly Instructions:( Refer to exploded view No. 10)

When disassembly of the actuator is required formaintenance, remove the actuator from the valve.Ensure proper lifting procedures are followed whenmoving or carrying actuators.When disassembling the Heavy Duty Actuatoractuators, use caution and be certain that theactuator is free from accessories and the air supply isdisconnected. When the actuator is a spring-returnunit, make sure that the actuator is in the failed

position before disassembling.1) Removal of Piston :a) Removetie rod lock nut (33)and tie rod (32).b) Remove endcap (34) from pneumatic cylinder.c) Remove pneumatic cylinder (28)d) Remove piston bolt (30).e) Remove piston (29) from piston rod (25).2) Removal of Spring Cartridge Assembly:a) Remove all spring cartridge studs (41) and nuts

(42).

b) Remove spring cartridge Assembly (44) frompiston rod (25).

3) Removal of Adapter Plate:a) Remove all adapter plate bolts (40).b) Remove adapter plate (27) from actuator body(01).4) Removal of Piston Rod :

a) Remove all housing cover screw (06).b) Remove housing cover (07) with housing cover

gasket (20) from actuator body.c) Remove yoke pin circlip (06) and housing roller

(21) from yoke pin.d) Remove yoke pin (04) from piston rod (25) and

yoke (03).e) Remove piston rod from actuator housing (01).5) Removal of Torque Shaft :

a) Remove Open and close indication tag plate(47) & (48).

b) For removal of bearing retaining plate (12),remove all bearing retaining screw (13).

c) Remove the needle bearing (11) andbearing housing (10)

d) Slightly tap with a mallet on the Yoke key(18) to free it from yoke and torque shaftassembly. remove the torque shaft (19).

FIG.4

PORT B

PORT A


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FIG. 6

6.2 Assembly Procedures :

The following procedure describes the assemblyprocedure for heavy-duty actuators.

1. Clean all the components and apply grease onthem.

2. Fit the Piston rod bearings (02), Needle bearings(11) with bearing Housings (01) in the piston rodbores and Torque shaft bores of the Housing(10) respectively.

3. Insert the yoke (03) in to the Housing (01). Andcentre the yoke in the mid or 45

o position as

shown in the Fig. 5

It is recommended to use the lubricants asmentioned below.

General Use : CASTROL GREASE - AP3

4. Insert the piston rod (25) and assemble piston rodwith yoke using yoke pin (04) & yolk rollers (05)Fig 5. Use circlips (06) to retain the yolk pin in itsposition.

5. Fit the piston to the piston rod using the pistonBolts (30).

6. Slide the cylinder over the piston and using thetie rods, tie rod lock nuts and endcap clamp thecylinder to housing (Fig 6).

7. Insert the torque shaft and fit it into the yoke (03)

using yoke key (18).8. Insert the needle bearings with bearing housings.

Secure them with bearing retainer and retainerscrews.

9. Cover the housing using housing cover gasket(20), housing cover screws (08).

10.Attach the open close indication plates.

SPRING RETURN ACTUATORS :

11. Insert the spring cartridge (44) on to the pistonrod taking care so as not to damage the pistonrod and clamp the spring cartridge to the housingusing cartridge studs (41) , nuts (42) and sprin

washer (43)

Note:Support the spring cartridge during assemblyon to piston rod to prevent the damage to the pistonrod.

DOUBLE ACTING ACTUATORS:

12. Insert the rod cover (44) on to the piston rodtaking care not to damage the piston rod. Securethe rod cover using lock washers (43) and rodcover bolts (41).

13. External Travel Stop Adjustment:

The Stroke Adjustment Bolt to the right controlsthe clockwise end of travel, while to the leftcontrols the counter-clockwise end of travel.

Cycle the actuator/valve to the clockwise end oftravel and measure to determine if the valve is inthe proper position. (In most of the applications,this will be fully closed)

If the valve is not in the correct clockwiseposition, turn the right stop adjustment bolt (15)IN to reduce actuator travel, or OUT to increaseactuator travel.

When the correct clockwise position is obtained,hold the adjusting bolt (15) stationary while

tightening the nut (16). Cycle the actuator/valve to the counter-clockwiseend of travel and measure to determine if thevalve is in the proper position. (In most of theapplications, this will be fully opened).

If the valve is not in the correct counter-clockwiseposition, turn the left stop adjustment bolt (15) INto reduce actuator travel, or OUT to increaseactuator travel. When the correct counter-clockwise position is obtained, hold the adjustingbolt (15) stationary while tightening the nut (16).

FIG. 5


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4

7. Cleaning and inspection:

When all components are disassembled, those notbeing replaced should be properly cleaned andinspected for wear prior to re-assembly. PROPER

LUBRICATION TO BE DONE PRIOR TOASSMEBLY.

8. Storage

All the Heavy Duty Actuators are factory lubricated.The ports are plugged to prevent material fromentering the actuator during the shipment. If theactuators are not for immediate use, the followingprecautions must be taken during storage.a) Store in a dry environment.b) It is recommended that the actuator be stored in

its original box.c) Do not remove the plastic plugs on the air supplyports.


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5

9. Part List


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6

10. EXPLODED VEIW


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Installation, Operation & Maintenance ManualDECLUTCHABLE MANUAL OVER-RIDE

1

M: 1 INSTALLATION:The Rotary Manual Over-ride mounts in betweenvalve and actuator. These are available in threemodels: RM-1, RM-2, RM-3. Selection of a model isbased on total torque of valve and actuatorcombination.

1. Before installation ensure that:

Coupling for valve to gear box and gear box toactuator are of proper fit. Keys to be used forengagement are of proper dimensions.

Coupling surface are smooth and slide easily inand out of sector gear. If required file /grindsurfaces lightly.

Sector gear movement accommodates entirevalve rotation / travel.

Valve is in fail safe position.

Following hardware is availableFor RM-1: M8/10x20 S.S.Hexbolt-8 No.

RM-2: M16x25 S.S. Hexbolt-8 No.

RM-3: M20x30 S.S. Hexbolt-8 No.Spring washers of relative size.

2. Before installation, operate gearbox (MOR) toensure the direction of rotation of sector gearmatches with the valve rotation (CW toClose/CCW to Open).

3. Mount bracket and coupling on the valve. Placegear box on valve coupling. The standardpractice is to position the gearbox with its handwheel parallel to pipe line and from port face ofactuator.

4. Align the slots on sector gear and coupling.Insert key for engaging coupling to sector gear.

5. Match the holes and insert bolts. Keep the bolts

finger -tight. For matching holes, if requiredrotate gearbox housing a few degrees throughhand wheel. Refer # M 2.1, to engage MOR forits operation through hand wheel.

6. Mount bracket over gearbox and bolt it. Keepthe bolts finger tight. Slide coupling over the keyto engage with sector gear.

7. Lower the actuator on coupling until it rest overthe bracket surface.

8. Match the holes, if required flow step # 5 andinsert bolts.

9. Further tighten all mounting bolts. Operatevalve 2-3 time manually-with gearbox to ensuresector gear movement accommodates the

entire valve travel from full open to closeposition.

10. Declutch the gearbox. Refer # M: 2.2. Strokeactuator pneumatically 2-3 times to allow self-alignment of couplings. Tighten all mountingbolts fully to avoid the relative movementbetween actuator to MOR and MOR to valve.Adjust actuator piston stroke at this time.

M:2 OPERATION:

Manual over-ride operates on Worm-Worm WheelMechanism. Multiturns of hand Wheel / Worm shaft

rotates Worm Wheel / Sector Gear through Quarterturn. Worm shaft is secured by means of Eccentric

bushes at its ends. 180 rotation (Half turn) ofEccentric Bushes shifts the worm shaft towards oraway fromthe worm wheel / sector gear to Clutch /Declutch. Refer the following instruction to clutch /declutch the MOR.

M: 2.1 MOR in Engaged Mode / Manual Mode:MOR can be engaged at any position over the entirevalve travel- Close /Open / Intermediate.

CAUTION!Before engaging MOR, cut off air supply to actuator to

ensure that the manual force through gearbox is notacting against pneumatic pressure.

Lift Lock Pin momentarily and rotate declutch Levera few degree to dislodge the pin tip from its seat /pin hole on Eccentric bush.

Release the lock pin and it will remain floating.

Further rotate declutch lever CW (towards

actuator) through 180 until the spring loadedlock pin drop down. Rotating lever CCW in thismode defeats the purpose.

Worm shaft is now engaged with sector gear.

CAUTION!Never apply excessive force to lift lock pin and to rotate

declutch lever. This may damage either of lock pin or

Eccentric bush permanently.

To make the declutch lever movement free andeasy; it may be necessary to turn the hand wheelslightly to mesh the gears.

Rotate the hand wheel CW / CCW to open / closevalve (Refer direction arrow on hand wheel).

Important!Before returning to pneumatic operation alwaysdeclutch MOR.

M: 2.2 MOR in Declutched Mode:

WARNING!: Never declutch MOR against springforce acting through actuator i.e. if a valve with MOR


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2

& spring return actuator is operated manually toopen (Fail to Close) the valve, do not try todeclutch MOR in this condition. Attempting thesame may lead to personnel injury or damages toMOR.

Lift the Lock pin and rotate Cl. / Declutch Lever

CCW (towards Valve) through 180 until thespring loaded lock pin drop down. Rotating leverCW in this mode defeats the purpose.

Confirm hand wheel rotates freely. Connect airsupply to actuator.

M: 2.3 Changing Fail Safe Condition ofValve / Orientation of Manual Over-ride:To meet above requirements, it is necessary todis-assembly gearbox unit to reposition the sectorgear. In continuation to IOM Instruction foractuator 4.3 refer the following instructions to

change fail safe condition of the valve assemblywith VALVE + MOR +Actuator.1. After changing fail safe condition of valve,

there are chances of mismatch of valvecoupling of keyway and sector gear keyway

by 90.2. Also the direction of rotation of valve, from

close to open or vice versa may get reversed.3. Under such conditions, disassemble gear box

housing by removing cap screws 08 nos.4. Remove sector gear and reverse it up side

down. This will shift the key way position. If

required further rotate sector gear by 90toensure the alignment of key ways.

5. Operate hand wheel to ensure the rotationof sector gear accommodates the new valvetravel as well as key ways on sector gear getaligned at both valve positions.

6. Re-assemble the housing. Follow # M: 1INSTALLATION to re-install the manualOverride. Operate valve + MOR manually 2-3time to re-assure the valve operation (opening/ closing) meets the new requirement.

M: 3 MAINTENANCE:The manual over rides are designed for long lifeand trouble free operation. User must attend thefollowing points to ensure smooth, trouble free &

maintenance free operation over a prolongedperiod.

The self locking pin locks and unlock just with

momentary lift and worm shaft rotate by 180in CW / CCW smoothly using declutched lever.

MOR operates smoothly and the desired valveposition is achieved by rotating the handwheel.

Check for smooth operation of valve whenMOR is declutched. If the operation of MOR is

not smooth, dis-assemble and lubricate withgrease.

After certain clutch / declutch operationsadjust length of pin tip protruding out of itshousing to ensure positive locking of pin withworm shaft.

M: 4 TROUBLESHOOTING: Actuator does not stroke

MOR is in engaged mode, Declutch it.Ensure sector gear is engaged with coupling toactuator.

Valve does not operate manually throughMOR:

Confirm MOR is in engaged mode and sectorgear is engaged with valve coupling.Confirm air supply to actuator is disconnected.

Cl./Declutch lever does not rotate freely, MORdoes not clutch / declutch:

Lift the lockpin. Rotate handwheel slightly tomesh the gears and rotate the leverssimultaneously to clutch / declutch MOR. Ensurepin locks positively with worm shaft. If pin tip isdamaged, replace it.

M: 5 LIST OF RECOMMENDED SPARES:1. Lock pin assembly2. Cl./declutch lever.3. Seal kit (consists of a pair of bush

bearings, o-rings to sector gear, worm shaft,

eccentric bushes) please specify MOR modelwhile ordering spares.

Please specify MOR model while ordering.


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3

PARTS & MATERIALS GEAR BOX ASSEMBLY MODEL- RM1 / RM2

Description Part No. Description Part No.

Body casing- Top & Bottom 6,1 Worm Shaft Assembly:Body Fastners 9,2Dowel Pins 23 Worm Shaft 13

O-Ring 24Sector Gear Assembly: Eccentric Bushes

-with collar on hand wheel side 15Sector Gear 5 - Rear Side 11Nylon Bush & O-Ring- Top & Bottom 3,4 Ecc.Bush Connecting rod 14

Cl./Declutch Lever 22Lock Pin Assembly: Ny. Bush & O-rings to Ecc. bush 12,10

Lock Pin 20 Handwheel: 25

Spring 19 Direction Indicating / Covering plate 16,18Adjuster Nut & Bolt 7,8 Handwheel Retaining Bolt 17Lock Pin Holder 21


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Installation, Operation & Maintenance ManualLIMIT SWITCH BOX.

IOM/LS/ATEX/06/REV.0

Limit Switch Box:The automated control valve is provided with limitswitch Box mounted on the top of actuator. Limitswitch box facilitates remote as well as localindication of valve position.

L: 1 INSTALLATION:Installation of Limit switch box on actuator is bestperformed using standard bracket for actuatorswith Namur mountings & with customizedbracket/couplings for actuators without Namurmounting.Mounting:Fix the housing to the bracket(M8 X 12 SSHexbolts-4 nos) Additional coupling is not requiredfor actuators with Namur mounting. As the bottomside of the shaft is designed to NAMURstandards, engage it directly with pinion. Bolt thebracket on top of actuator (M5 x 12 S.S. Hex-4nos)

for Non-Namur actuators use coupling to engageSwitch Box shaft with actuator pinion. Bolt thebracket on top of actuator(M5 X 12 SS Hexbolts 4 nos)

Fix all the bolt and tighten them evenly. Ensurebracket faces are resting properly on actuator topand there is no building of stresses on coupling orshaft. Confirm the local indication (Open / Close)on pharos indicator match to that of valve position.

Insert the cable through cable gland and connectit to the terminal strip. (Refer Wiring Diagram).

The switch box is provided with two cable entries(third one is optional & can be provided ondemand), if only one cable entry is to be used,plug the other properly


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L: 2 OPERATIONS:

L: 2.1 Switch SettingThe switch box encloses limit switches/sensors,(no.of limit switches varies with application &customer requirement), prewired to terminal strip.The switch are pre-set to indicate Open and Closevalve position. Bottom switch indicates Closeposition while top switch indicates Open positionof valve.Before setting switches, isolate electric supply andremove top cover of switch box. To remove topcover loosen the four screws on clamping ring.Then remove clamping ring & then outer dome.Now remove inner dome which is engaged withstem. Rotate the top cover by hand in anti-

clockwise direction till it gets free from housing.With top cover removed, there will be clear accessto cam & limit switches.Bottom Switch Setting: Lift the lower cam to dis-engage the splines and turn it CW until the switchisactivated (i.e. electro mechanical switch should bepressed fully or proximity sensors should beactivatedto complete the circuit- in some models, inbuiltLED glows ON when sensor is activated.)Release the cam and make sure it will engagewith the splines.Top Switch Setting: Stroke the actuator to full

CCW position. Depress the upper cam to dis-ngage the splines and turn it CCW until the switchis activated. Release the cam.

Confirm the changeover of switch contact withmultimeter by stroking actuator 2-3 times.The cams are provided to activate the switches at

0& 90valve travel but can be adjusted to

indicate any position between 0and 90valvetravel.

L: 2.2 PHAROS VISUAL POSITION INDICATORADJUSTMENT:1. Note Valve/actuator position before starting.2. Loosen the screws on clamping ring & match

the open/close position windows on inner &outer dome.

3. Tighten the screws on clamping ring to fixopen/close position.

4. If dome window still does not line up, repeatsteps #2-3.

5. For best visibility, wipe dome periodically with adamp non-abrasive cloth.

L: 2.3 Switch Options:A. Electro Mechanical Switches-------------------------------------------------------------------Switch Type Switch Chararacteristics Qty.-------------------------------------------------------------------V-5 SPDT-10A/250VAC 2-NSW

- 0.5A/125VDC 4-LSW-0.25A/250VDC

B. Namur Proximity Switch (Intrinsically Safe):-------------------------------------------------------------------Switch Type Switch Chararacteristics Qty-------------------------------------------------------------------SJ3,5-N Slot type. 2 Wire, 2

NJ2-V3-N Rect.type,2 Wire, 2

Apart from above, other switch options can beprovided as per customers requirement.

L: 3 TROUBLESHOOTING :

The limit switch box is designed to provide troublefree / maintenance free service. However thefollowing probable causes and solutions may helpthe user to sort out the typical problem faced atcommissioning stage:a. Switching operation not reliable:

Operate / press switches (electro-mechanical)manually and check the contact changeover atswitch terminal as well as at PCB terminal strip.

Caution!Never apply excessive force to engage/ dis-engage cams, this may damagecam / gear permanently

CAUTION!

Some acids, caustics andhydrocarbons can discolor or causestress revealing damage.


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If switches are OK, set the cams properly topress switches fully.

If contact changeover is not observed even byoperating switches manually, replace theswitches.

b. Switch setting changes frequently:

Confirm that gear on spindle are intact andthere is no slippage between spindle and gear.

If gears are damaged, replace the spindleassembly.

c. Local indication is not proper / changesFrequently :

Loosen the clamping ring. Match the windowon inner & outer dome. Toghten the screwson clamping ring.

Precautions:

a. Always close the top cover of enclosure byrotating it fully.

b. Confirm O-ring to top cover, Outer dome isintact and placed properly.

c. Plug the unused cable entry.d. Use cable of proper sheath / insulation

thickness suitable for cable gland providedalong with switch boxes.

e. Never hammer pharos indicator cover.f. Insulate electric supply to limit switches before

opening top cover.

L: 4 LIST OF RECOMMENDED SPARES:

Limit switches

O-rings Local position indicator assembly

Note:- While ordering spares, please specifymaterial of box, type and no. of limit switchesprovided.


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LSW


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H.O. & WORKS: VIRGO ENGINEERS LIMITED

Survey No. 277, Raisoni Industrial Park, Phase-2, Hinjewadi, Pune-57

Tel.: (020) 66744000,Fax : (020) 66744021

E-mail : [email protected]

Website : www.virgoengineers.com

WORKS: VIRGO VALVES & CONTROLS LIMITEDSurvey No. 277, Raisoni Industrial Park, Phase-2, Hinjewadi, Pune-57

Tel.: (020) 66744000,

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